Recycled crosslinked vinyl-alcohol polymer coated films and methods to manufacture the same

Abstract

Embodiments herein relate to a polyolefin-containing film comprising a solidified form of a melt, the melt comprising at least 1 weight percent shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material and an amount of a compatibilizing agent and/or an un-crosslinking agent configured to un-crosslink the crosslinked vinyl-alcohol in the melt, the polyolefin-containing film having an average dimple count of less than about 50 dimples/4 in 2 , and method of manufacturing the same.

We claim: 
     
       1. A polyolefin-containing film comprising a solidified form of a melt, the melt comprising at least 1 weight percent shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material and an amount of an un-crosslinking agent configured to un-crosslink the crosslinked vinyl-alcohol in the melt, the polyolefin-containing film having an average dimple count of less than about 50 dimples/4 in 2 . 
     
     
       2. The polyolefin-containing film of  claim 1 , wherein the polyolefin-containing film has an average dimple count of about 30 dimples/4 in 2 . 
     
     
       3. The polyolefin-containing film of  claim 1 , wherein the melt contains at least 5 weight percent of the shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material. 
     
     
       4. The polyolefin-containing film of  claim 1 , wherein the compatibilizing agent comprises polyethylene grafted or copolymers that contain ester or acetate groups. 
     
     
       5. The polyolefin-containing film of  claim 1 , wherein the un-crosslinking agent comprises water. 
     
     
       6. The polyolefin-containing film of  claim 1 , wherein the shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material comprises both water and the compatibilizing agent. 
     
     
       7. The polyolefin-containing film of  claim 1 , wherein the melt comprises 1 to 10 parts by weight of the compatibilizing agent and/or 1 to 10 parts by weight of the un-crosslinking agent for 100 parts of the shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material. 
     
     
       8. The polyolefin-containing film of  claim 1 , wherein the vinyl-alcohol coated polymer comprises PVOH, EVOH, or blends thereof. 
     
     
       9. The polyolefin-containing film of  claim 8 , wherein the EVOH contains 10% ethylene or less. 
     
     
       10. A laminate film comprising the polyolefin-containing film of  claim 1  and a metal-containing layer. 
     
     
       11. The polyolefin-containing film of  claim 1 , further comprising a compatibilizing agent. 
     
     
       12. A laminate film comprising the polyolefin-containing film of  claim 11  and a metal-containing layer. 
     
     
       13. A polyolefin-containing film comprising a solidified form of a melt, the melt comprising at least 1 weight percent shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material and an amount of an un-crosslinking agent configured to un-crosslink the crosslinked vinyl-alcohol in the melt, wherein the polyolefin-containing film does not contain a compatibilizing agent, the polyolefin-containing film having an average dimple count of less than about 50 dimples/4 tn 2 . 
     
     
       14. A polyolefin-containing film comprising a solidified form of a melt, the melt comprising at least 1 weight percent shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material and an amount of an un-crosslinking agent configured to un-crosslink the crosslinked vinyl-alcohol in the melt, the polyolefin-containing film having an average dimple count of less than about 50 dimples/4 in 2 . 
     
     
       15. The polyolefin-containing film of  claim 13 , wherein the melt contains at least 5 weight percent of the shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material. 
     
     
       16. A laminate film comprising the polyolefin-containing film of  claim 13  and a metal-containing layer. 
     
     
       17. The polyolefin-containing film of  claim 14 , wherein the melt contains at least 5 weight percent of the shredded recycled crosslinked vinyl-alcohol polymer coated polyolefin material. 
     
     
       18. A laminate film comprising the polyolefin-containing film of  claim 14  and a metal-containing layer.